Method of constructing an article of furniture

ABSTRACT

A method of constructing an article of furniture having at least a basic substantially horizontal frame comprises forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into the gap and subsequently securing the spacers to the members so as to permanently maintain the members in their relationship and thereby provide the basic frame, and attaching of a supporting leg assembly to the basic frame.

United States Patent Clark Aug. 28, 1973 METHOD OF CONSTRUCTING AN ARTICLE OF FURNITURE Edward L. Clark, Raleigh, NC.

Research Corporation, New York, NY.

Oct. 27, 1971 inventor:

Assignee:

Filed:

Appl. No.:

11.8. C1. 144/314 B, 144/309 L, 144/318, 29/455, 156/292 Int. Cl B271 7/00 Field of Search 297/445, 452; 144/309 L, 309 Q, 309, 314 B, 318, 313; 156/292, 290, 91, 293; 29/455, 469

References Cited UNITED STATES PATENTS l/1952 Perry et a1. 9/1967 Bemro et a1. 5/1932 Butzen 144/318 X Primary Examiner-Andrew R. Juhasz Assistant Examiner-W. D. Bray Attorney-Harold L. Stowell and Thomas Jr. Greer.

[5 7] ABSTRACT A method of constructing an article of furniture having at least a basic substantially horizontal frame comprises forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into the gap and subsequently securing the spacers to the members so as to permanently maintain the members in their relationship and thereby provide the basic frame, and attaching of a supporting leg assembly to the basic frame.

10 Claims, 7 Drawing Figures PATENIEDMIS28 I975 SHEEI 1 [1F 4 FIG].

FIG. 2.

IN VENTOR 1, an ATTORNEYS PATENTED M1828 I875 SHEET 2 0F 4 INVENTOR EDWARD L. CLARK |6 BY X2. ATTORNEY PATENIED MIS 28 I973 SHEEI 3 OF 4 R O T N E V m EDWARD L. CLARK ATTORNEY sirsagsaeg PATENIEU M1828 I973 saw u or 4 INVENTOR EDWARD L. CLARK ATTORNEYS METHOD OF CONSTRUCTING AN ARTICLE OF FURNITURE BACKGROUND OF THE INVENTION 1. Field Of The Invention The present invention generally appertains to novel improvements in the construction of articles of furniture and especially relates to a new and novel foundation or frame construction and method of forming the same in the manufacture of articles of furniture, such as chairs, sofas, couches and the like, irrespective of the external appearance or formation of such articles of furniture.

2. State Of The Prior Art In the usual manufacture of furniture, the vast majority of the frames are made of wood. This is particularly true of frames used in the construction of upholstered articles of furniture, such as chairs and sofas. Wood as a raw material has the attributes of being relatively inexpensive, easily machines and has excellent tack or staple holding properties for the attachment of upholstery fabric.

Furniture designed with straight lines is made most economically of wood. When designs require any degree of curvature, such as curved bases, the wood parts must be machined and such machining not only slows down the construction of the furniture but also, due to the labor factor, adds to the cost of manufacture. A common example of such slow and expensive construction is the so-called barrel chair In such construction, the curved parts, such as the base seat frame, are made of bandsawn and dowelled segments cut from large and heavy blocks of solid or laminated wood. The high labor cost and the very large waste factor have made the cost of such barrel chairs or any chairs or sofas wuth curved base frame rise steeply in recent years.

In the manufacture of upholstered furniture, the many parts, which make up the basic frame structure, must be completely assembled before any upholstering can be commenced. Also, the job of the upholsterer is very much complicated by having to tailor the fabric around the many structural members and braces of the conventional frame.

In addition, with present manufacturing techniques that require the machining of parts in forming the frames, there is a restriction on designing since there is always a concern for the breaking of the wood parts due to short grain on curved parts.

SUMMARY OF THE INVENTION A primary object of the present invention is to provide a sub-assembly or built-up section technique for the construction of articles of furniture, such as chairs, sofas, couches and the like, whereby a reduction in material and labor costs and time of manufacture can be realized along with a reduction in weight of the finished articles of furniture and whereby an increase in the strength of such finished articles can also be obtained.

The construction technique of this invention produces a reduction in weight of the furniture from about one-fourth to about one-half over conventionally constructed and assembled furniture of the same class and nature, such as a barrel chair. Such technique, also, provides about double the strength of a chair formed thereby over a conventionally constructed chair, for example, with the same being true of sofas and the like and other articles of furniture. Also, with the manufacturing technique of the present invention, the production costs are reduced over conventional manufacturing techniques from about one-fourth to about onehalf.

Another primary object of the present invention is to provide a manufacturing technique for constructing upholstered articles of furniture, like chairs and sofas, whereby such articles are formed from sections that are constructed and upholstered as completed subassemblies which are joined together to form the complete and final articles.

Such construction technique will permit a significant reduction in manufacturing and inventory costs to be achieved since, for example, the same base construction can be used with a number of differently styled and designed arm and back sections. Also, a common base construction can be used with differently styled legs. For example, the same frame can be merchandised with Contemporary, Mediterranean, Traditional or other styples by merely attaching the appropriate set of legs to the common frame.

Basic to the novel manufacturing technique of the present invention is the formation of the base seat frame from two concentric or parallel bands or strips fabricated of veneer or other suitable material of plywood, plastic, metal, paper or the like material with the bands being joined in spaced apart andnested relation by bridging or spacer elements that are fixed in the gap between the bands. The spaces of the gap between the connecting bridging or spacer elements can, if desired, define sockets for the fixed reception of tenons or arm frames, back frames and leg assemblies.

For example, a pair of plywood strips or a plurality of strips of wood to form a pair of plywood strips are formed into arcuate shapes over a mandrel or form to the desired contour. One of the strips is formed so as to be smaller than the other such that when the pair of strips are placed in non-contacting juxtaposition there is a uniform "/8 inch gap between them at all points. The strip of smaller shape is nested inside the other when the strips are assembled into a concentric relationship and there is a resultant and uniform gap of 78 inch between the two strips. Blocks of wood inch square and ofa given length (usually 3 to 6 inches long) can be inserted vertically in the gap between the strips. These blocks can be glued and/or stapled or otherwise fastened at a number of desired locations to provide a strong, light-weight and inexpensive structure. The blocks not only serve as bridging blocks that interconnect the strips but they can also serve as fastening points for springs and as locator stops for the insertion of the mounting ends ofthe arm frames, the back frame and the legs.

The same technique for the formation of the basic seat frame can be extended to and used in the construction of the arm frames, the back frame and other components.

The various frames are formed and completed, as by being individually and separately upholstered, and then in assembling the frames into a complete and final chair, for example, small cuts can be made in the covering fabric for the seat frame to permit tenons formed on the arm and back frames to be inserted into the gap between the two base strips or members. With regard to the foregoing example, the tenons or other machined end constructions would be "/8 inch thick. Suitable fasteners inserted through the inside of the base frame into the tenons serve to hold the arm frames and back frame to the base frame. Legs would be formed with machined upper ends, either tenons or bifurcations, that would have /3 tenons to fit into the gap and be attached by fasteners such as conventional nails, wood screws, staples, bolts and the like.

Thus, it can be appreciated that a very important object of the present invention is to provide a new and novel chair, sofa or the like article of furniture construction and to provide a simple, easy and inexpensive method of manufacturing such article of furniture, with the method being basically applicable to the formation of any articles of furniture that have a basic horizontal base frame assembly from which vertical supports, such as legs, depend, as in the case of an ottoman, foot stool, or even a table.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a frontal perspective view of an assembled and partially upholstered chair which is a swivel rocker, that is formed and constructed in accordance with the present invention, and which is illustrated without the conventional rocker swivel base.

FIG. 2 is a rear perspective view of the chair shown in FIG. I.

FIG. 3 is an exploded perspective view of the chair of FIG. 1 and showing the various frame sections in unassembled and detached relationship.

FIG. 4 is a side perspective view of a wing-back chair, which is formed in accordance with the present invention and showing the same in an assembled but unupholstered condition.

FIG. 5 is a frontal perspective view of the assembled back and seat frame of the chair shown in FIG. 4.

FIG. 6 is an exploded perspective view of another chair formed in accordance with the present invention and illustrating the unassembled sections in positions for assembling and with some of the sections being shown in an upholstered condition.

FIG. 7 is a frontal perspective view of the back frame section of the chair shown in FIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now more particularly to the accompanying drawings, and initially to FIGS. 1-3, the chair frame 10 is for a wing type swivel rocker, which is not shown in its final, completed form. The chair frame 10 in cludes a base frame 12, that also constitutes the seat frame, and which is formed from inner and outer concentrically arranged arcuate bands or strips 14 and 16, respectively. The inner strip 14 is shorter than the outer strip 16 and is nested therein with a space or gap 18 being provided between the strips.

The strips 14 and 16 are permanently fixed in their nested concentric relationship by bridging blocks 20 which are inserted into the gap 18 at the illustrated spaced apart locations and fixed to the inner confronting faces of the strips by glue or other fastening means. Fasteners, such as nails, can be used and would be driven into the blocks from both sides of the U-shaped base frame 12.

The outer ends of the leg portions 22 and 24 of the inner arcuate strip 14 and the other ends of the leg portions 26 and 28 on FIG. 3 of the outer arcuate strip 16 are connected by a cross slat 30 that closes off the open front end of the U-shaped base frame and serves as the straight front end for such frame. The slat 30 has its ends butted up against the insides of the outer ends of the leg portions of the outer strip 16 and secured thereto by fastening nails 32 or other means, while the slat faces over the outer ends of the leg portions of the inner strip 14.

A base board 34 is disposed beneath the base frame and extends from the front slat to the bight portion 36 of the base frame with the base board being attached to the coplanar lower edges of the cross slat and the inner and outer strips. The base board 34 serves as the means for attaching the base frame to a swivel rocker base, which is a conventional piece of furniture hardware and, for this reason, is not illustrated.

The chair frame 10 further includes a back frame 38 that is composed of a top section 40 which is con structed in a manner similar to the formation of the base frame. The top back section 40 includes inner and outer strips or bands 42 and 44, respectively, that are spaced apart in a nested relationship to provide a gap 46 in which bridging blocks 48 are fixedly inserted to maintain the strips in their spaced apart relationship. The outer open ends 50 of the gap 46 are closed by the inserted inner end portions 52 of solid wood ears or wings 54. The inner end portions 52 are socketed in the open ends of the gap 46 in a manner so that the ears 54 protrude from the gap as axial prolongations of the top back section 40. The inserted end portions are fixed to the ends of the strips 42 and 44 by fasteners 56.

The inner socketed ends 52 of the ears or wings 54 are formed with vertical notches 58 which fixedly receive the tenons 60 on the upper ends of vertical back posts 62. The lower ends of the back posts 62 are bifurcated with such bifurcated lower ends 64 being attached to the base frame. The bifurcated ends straddle the inner strip 14 of the base frame at the junction between the bight portion and the leg portions with one bifurcation 64a being vertically socketed in the gap 18 and the other bifurcation 64b being vertically disposed along the inner face of the strip 14. Fasteners 64 secure the lower ends 64 of the back posts to the base frame.

The ears or wings 54 have sockets (not shown) vertically formed in their undersides into which the upper ends of angularly declined tumings 66 are fixedly fitted with the lower ends of the tumings socketed in the gap of arm frame 70. The upper end of upright 68 is socketed in the gap of arm frame 70 and the lower end of upright 68 is socketed in gap 14 to the base frame 12.

Arm frames 70 are provided and each of such arm frames includes an inner arm slat 72 that is constituted by the leg portions of an arcuate band 74 which is fixed within transverse notches 76 formed on the inner sides of the vertical back posts 62. The bight portion 78 of the band 74 serves as a curved support for the back frame 38 and is bent on the same radius as the outer strip 16 which it overlies.

Each arm frame 70 further includes an outer arm slat 80 which has its end portion 82 fitted in a transverse notch 84 formed in the outer face of each of the vertical back posts 62 at a point coinciding with the placement of the notches 76. The arm slats are interconnected by filler blocks 86 and have transversely spaced apart outer ends 88 that define a socket which is closed off and filled by an inserted horizontal tongue 90 attached to the upper end of an arm knuckle 92. A shaped block is fastened to outer slat 80 as a style feature of this type chair. The lower end portions of the arm knuckles 92 have tenons 96 which are fixedly fitted within the gap 18 of the base frame 12 adjacent the cross slat 30. The socketed tenons 96 are fixed by suitable fasteners within the receiving gap 18.

A U-shaped center rail 98 is fixed to the inner faces of the lower end portions 94 of the arm knuckles and to the blocks 69, as shown in FIGS. 1 and 2.

After the frame sections are assembled, as shown in FIG. 1, the frame sections are covered with an upholstery fabric 100 with the solid wood wings 54 and arm knuckles 92 being left exposed. Of course, the various frame sections can be designed to be upholstered in separate fashion before they are assembled together to form the entire chair frame.

In the construction of the base frame 12, the bands or strips 14 and 16 which are formed from thin wood strips, plastic, paper or similar material are formed over a mandrel, wound about a mandrel or form to the desired U-shaped contour with the inner strip being smaller, as, for example, /8 inch, than the outer strip. When the smaller inner strip 14 is nested within the outer strip 16, this produces the uniform gap 18 which would be "/8 inch. In such instance, the bridging blocks would be solid wood blocks of "/8 inch square and of the required length, predicated upon the vertical extent of the strips, usually about 3 to 6 inches. The, blocks are inserted vertically in the gap 18 and are glued and/or stapled or otherwise fastened at a number of spaced apart locations, as illustrated.

The bridging blocks may be disposed transversely and may be positioned in other fashion between the strips, since they need not run transverse to the longitudinal surfaces of the spaced apart strips or frame members l4 and 16. In any position, the blocks 20 not only serve as bridging and connecting blocks between the strips or frame members but they also are employed as fastening points for the attachment of springs (not shown). Various types of springs may be used including No-Sag; drop-in spring units or fouror eight-way hand-tied coil springs and webbing.

In another formation, the base frame could be formed of plastic with the concentric strips or frame members and bridging blocks or other spacers being formed integrally as part of a unitary whole.

In the form shown in FIGS. 4 and 5 of the accompanying drawings, the wing-back chair frame 10a includes a base frame 12a which is constructed the same as the base frame 12 of FIGS. l-3 but which is supported by vertical legs 102. The legs 102 have upper bifurcated ends 104 that vertically straddle the inner strip or base frame member 14a with the bifurcation 104a socketed in the gap 18a and the bifurcation 104b engaging the outer face of the inner strip 14a. Suitable fasteners secure the bifurcated ends 104 in place so that the base frame is. securely supported by the legs 102.

The chair frame 10a further includes a back frame 106, as shown in more detail in FIG. 5. The back frame 106 is composed of a top back section 108 which is constructed similar to the top back section 40 of the back frame 38 of the chair frame 10 of FIGS. 1-3. The ends of the top back section 108 are attached to blocks attached to the side of vertical back posts 110. The posts have bifurcated lower ends 112 fitted over the inner strip 14a at the ends of the bight portion 36a of the base frame 12a.

The back posts 110 have their front and back faces formed with transverse notches 114 and 116 at verti cally coinciding points into which the concentric bands 118 and 120 of the arm rests 122 are fitted and secured. The arm rests are supported by vertical arm posts 124 which have their lower ends bifurcated, as at 126, so that they fit in the gap 180 and engage the inner strip or member 14a of the base frame 12a.

An arcuate center band 128 has its ends fixed in notches 130 formed in the inner sides of the arm posts 124 and its web portion 131 supported by blocks 132 that are attached to and extend forwardly from the back posts 110 adjacent the base frame 12a.

Wing slats 134 are provided and have their lower ends attached to the tops of the arm rests with their upper ends attached to the top of the back posts 110.

In the form of the invention shown in FIGS. 6 and 7, the side fames 138 are made entirely separately and are composed simply of top arm rests 140 joined by vertical bars 142 to bottom base bars 144. Thus, the side frames are merely simple open rectangular frames which are covered with upholstery fabric 146. Mounting tenons 148 depend from the vertical bars 142 and are left exposed so that they can be socketed in the gap 18b of the base frame 12b when the various frame sections are assembled.

The chair 10b of FIGS. 6 and 7 has supporting legs 150 that have upper tenon ends 152 which are adapted to be socketed in and secured within the gap 18b. The chair, also, has a back frame 154 that has a center framework 156 from the sides of which wing frames 1S8 extend. The wing frames have tenons 160 on their base portions with the tenons being adapted to be socketed in and secured within the gap 18b of the base frame. The entire back frame is covered with upholstery fabric 162, after being completed, with only the tenons 160 being left exposed along with mounting base ends 164 provided on the back posts 166. The base ends 164 are formed with vertical slits 168 that receive the inner strip of the base frame and define tenons 170 that fit in the gap 18b.

The base frame 12b of the chair frame l0b is actually formed from two identical halves so that it is formed widthwise in two halves, with each half or section being similar in construction to the basic base frame 12 of FIGS. 13. Thus, each section 172 and 174 is U-shaped or arcuate and is composed of arcuate inner and outer concentrically arranged strips or hands 176 and 178 which are in spaced nested relation to produce the gap 18b that is filled at spaced points by bridging blocks 180 that interconnect the strips.

The sections 172 and 174 are disposed so that their open ends are in end to end relation and their adjoining open ends are joined by connecting blocks 182 that fit in the open ends and are fastened thereto. The connecting blocks can be of various lengths so as to govern the width of the base frame. In this fashion, sofas and couches are formed from two base sections, like the base frame 12, that are joined together at their mating or spaced apart but adjoining open ends. The spacing between the open ends of the sections is determined by the length of the connecting blocks which, in the case of long sofas, can be of considerable extent. For frames with ovate shape the base frame 12b may also be made with bands 176 and 178 formed as closed loops with a 360 wrap around.

The base frame 12b is covered with an upholstery fabric 184 and cuts are made in the fabric, after the base frame is entirely covered, so as to enable the tenons on the side frames, the back frame and legs to be inserted into the gap 18b and fastened therein when the various frame sections are assembled.

While various forms of the invention have been described herein and shown in the accompanying drawings, such is merely exemplary of the invention, that is not to be limited thereby or by the Abstract but which is solely to be determined by the scope and spirit of the appended claims.

What is claimed is:

l. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attaching of a supporting leg assembly to said basic frame so as to support it on a supporting surface.

2. The method of claim 1 wherein said leg assembly is fitted in the gap between the members and secured therein.

3. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attachment of a back frame to said basic frame.

4. The invention of claim 3 wherein said back frame is fitted in the gap between the members and secured therein.

5. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging 8 spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attachment of a back frame and side arm frames to said members.

6. The invention of claim 5 wherein said back and side arm frames are fitted in the gap between the members and secured therein.

7. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of striplike members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, wherein said members are formed in a U-shaped formation and have outer open ends and closing off said ends with a cross member arranged transversely thereto.

8. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, wherein said members are formed in a substantially U-shaped formation and have web portions and open ends and a pair of said thusly formed frames are disposed in adjoining relation with their open ends in confronting relation and securing said adjoining ends together by bridging the distance therebetween with connecting spacers attached to said open ends of the frames.

9. The invention of claim 8 and including the attachment of back and side frame members to said frames with said back and side frame members being fitted in the gaps of said frames and secured therein.

10. The invention of claim 8 and including the attachment of leg assemblies to said frames with said leg assemblies being fitted in the gaps of said frames and secured therein. 

1. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attaching of a supporting leg assembly to said basic frame so as to support it on a supporting surface.
 2. The method of claim 1 wherein said leg assembly is fitted in the gap between the members and secured therein.
 3. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attachment of a back frame to said basic frame.
 4. The invention of claim 3 wherein said back frame is fitted in the gap between the members and secured therein.
 5. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, and attaChment of a back frame and side arm frames to said members.
 6. The invention of claim 5 wherein said back and side arm frames are fitted in the gap between the members and secured therein.
 7. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, wherein said members are formed in a U-shaped formation and have outer open ends and closing off said ends with a cross member arranged transversely thereto.
 8. The method of constructing an article of furniture having at least a basic substantially horizontal frame comprising the forming of a pair of strip-like members into a nested inner and outer spaced apart relation so as to produce a gap therebetween, inserting bridging spacers into said gap and subsequently securing said spacers to said members so as to permanently maintain said members in their relationship and thereby provide the basic frame, wherein said members are formed in a substantially U-shaped formation and have web portions and open ends and a pair of said thusly formed frames are disposed in adjoining relation with their open ends in confronting relation and securing said adjoining ends together by bridging the distance therebetween with connecting spacers attached to said open ends of the frames.
 9. The invention of claim 8 and including the attachment of back and side frame members to said frames with said back and side frame members being fitted in the gaps of said frames and secured therein.
 10. The invention of claim 8 and including the attachment of leg assemblies to said frames with said leg assemblies being fitted in the gaps of said frames and secured therein. 